Magnetic recording layer formulation for tape media

ABSTRACT

A product, according to one approach, includes a recording layer. The recording layer includes encapsulated nanoparticles each comprising a magnetic nanoparticle encapsulated by an encapsulating layer. A polymeric binder binds the encapsulated nanoparticles. A product, according to another approach, includes a recording layer. The recording layer includes encapsulated nanoparticles each comprising a magnetic nanoparticle encapsulated by an encapsulating layer, and a polymeric binder binding the encapsulated nanoparticles. An average diameter of the magnetic nanoparticles is in a range of 2 nanometers to 20 nanometers. An average thickness of the recording layer is less than 0.2 microns.

BACKGROUND

The present invention relates to data storage systems, and moreparticularly, this invention relates to magnetic recording layers fortape media.

In magnetic storage systems, magnetic transducers read data from andwrite data onto magnetic recording media. Data is written on themagnetic recording media by moving a magnetic recording transducer to aposition over the media where the data is to be stored. The magneticrecording transducer then generates a magnetic field, which encodes thedata into the magnetic media. Data is read from the media by similarlypositioning the magnetic read transducer and then sensing the magneticfield of the magnetic media. Read and write operations may beindependently synchronized with the movement of the media to ensure thatthe data can be read from and written to the desired location on themedia.

An important and continuing goal in the data storage industry is that ofincreasing the density of data stored on a medium. For tape storagesystems, that goal has led to increasing the track and linear bitdensity on recording tape, and decreasing the thickness of the magnetictape medium. However, the development of small footprint, higherperformance tape drive systems has created various challenges rangingfrom the design of tape head assemblies for use in such systems todealing with tape dimensional instability.

SUMMARY

A product, according to one approach, includes a recording layer. Therecording layer includes encapsulated nanoparticles each comprising amagnetic nanoparticle encapsulated by an encapsulating layer. Apolymeric binder binds the encapsulated nanoparticles. Various benefitsof a magnetic recording product having the new recording layer include,but are not limited to, one or more of: thinner recording layer, moreuniform magnetic particle dispersion, smoother, less turbid interfacebetween the underlayer and recording layer, higher glass transitiontemperature, lower occurrence or essential elimination of voids ofmagnetic particles in the recording layer, etc. Each of these benefitsresults in a magnetic recording product, such as tape, that exhibitscharacteristics such as, but not limited to, one or more of: improvedtear resistance, higher recording resolution down to and below 1 nm,lower noise resulting in a higher signal to noise ratio, etc.

In one aspect, an average thickness of each encapsulating layer is lessthan 1 nanometer. Such thin shells improve magnetic particle packingdensity in the recording layer, and thus enable higher recorded bitresolution.

In another aspect, no wear particles are present in the under layer.Such wear particles have been found to constitute an increasinglyintolerable defect and source of damage to the shrinking read and writestructures in current and future recording heads.

In another aspect, the product includes an underlayer, the recordinglayer being formed on the underlayer. The recording layer issubstantially not intermixed with the underlayer. This feature overcomesa longstanding problem in magnetic recording tape products, namelyintermixing of the layers at their interface and the well known problemssuch intermixing creates.

In one aspect, the underlayer is electrically conductive. Theelectrically conductive characteristic of the underlayer assists indissipating the charge, e.g., by transporting the charge to a hubcoupled to a ground, thereby minimizing charge traveling into the headand consequently lessening the risk of condensed liquid water forming aconductive path between the tape and head surface that provides a pathfor the electrochemical corrosion of the recording head structures.

In a preferred aspect, the recording layer is part of a magneticrecording tape.

A product, according to another approach, includes a recording layer.

The recording layer includes encapsulated nanoparticles each comprisinga magnetic nanoparticle encapsulated by an encapsulating layer, and apolymeric binder binding the encapsulated nanoparticles. An averagediameter of the magnetic nanoparticles is in a range of 2 nanometers to20 nanometers. An average thickness of the recording layer is less than0.2 microns. Various benefits of a magnetic recording product having thenew recording layer include, but are not limited to, one or more of:thinner recording layer, more uniform magnetic particle dispersion,smoother, less turbid interface between the underlayer and recordinglayer, higher glass transition temperature, lower occurrence oressential elimination of voids of magnetic particles in the recordinglayer, etc. Each of these benefits results in a magnetic recordingproduct, such as tape, that exhibits characteristics such as, but notlimited to, one or more of: improved tear resistance, higher recordingresolution down to and below 1 nm, lower noise resulting in a highersignal to noise ratio, etc.

Other aspects and approaches of the present invention will becomeapparent from the following detailed description, which, when taken inconjunction with the drawings, illustrate by way of example theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic diagram of a simplified tape drive system.

FIG. 1B is a schematic diagram of a tape cartridge according to oneaspect of the present invention.

FIG. 2A illustrates a side view of a flat-lapped, bi-directional,two-module magnetic tape head according to one aspect of the presentinvention.

FIG. 2B is a tape bearing surface view taken from Line 2B of FIG. 2A.

FIG. 2C is a detailed view taken from Circle 2C of FIG. 2B.

FIG. 2D is a detailed view of a partial tape bearing surface of a pairof modules.

FIG. 3 is a partial tape bearing surface view of a magnetic head havinga write-read-write configuration.

FIG. 4 is a partial tape bearing surface view of a magnetic head havinga read-write-read configuration.

FIG. 5 is a side view of a magnetic tape head with three modules wherethe modules all generally lie along about parallel planes.

FIG. 6 is a side view of a magnetic tape head with three modules in atangent (angled) configuration.

FIG. 7 is a side view of a magnetic tape head with three modules in anoverwrap configuration.

FIGS. 8A-8C are schematics depicting the principles of tape tenting.

FIG. 9 is a representational diagram of files and indexes stored on amagnetic tape in accordance with one aspect of the present invention.

FIG. 10 is a partial cross-sectional view of the basic structure of amagnetic recording medium, in accordance with various approaches.

FIG. 11 is a plot depicting Dynamic Mechanical Analysis (DMA) ofcoatings to determine the Critical Pigment Volume Concentration (CPVC),according to various approaches.

FIG. 12 is a transmission electron microscope (TEM) image of a crosssection of a conventional recording tape.

DETAILED DESCRIPTION

The following description is made for the purpose of illustrating thegeneral principles of the present invention and is not meant to limitthe inventive concepts claimed herein. Further, particular featuresdescribed herein can be used in combination with other describedfeatures in each of the various possible combinations and permutations.

Unless otherwise specifically defined herein, all terms are to be giventheir broadest possible interpretation including meanings implied fromthe specification as well as meanings understood by those skilled in theart and/or as defined in dictionaries, treatises, etc.

It must also be noted that, as used in the specification and theappended claims, the singular forms “a,” “an” and “the” include pluralreferents unless otherwise specified.

The following description discloses various configurations of layersparticularly useful in magnetic recording media, as well as methods forforming the layers.

In one general approach, a product includes a recording layer. Therecording layer includes encapsulated nanoparticles each comprising amagnetic nanoparticle encapsulated by an encapsulating layer. Apolymeric binder binds the encapsulated nanoparticles.

In another general approach, a product includes a recording layer. Therecording layer includes encapsulated nanoparticles each comprising amagnetic nanoparticle encapsulated by an encapsulating layer, and apolymeric binder binding the encapsulated nanoparticles. An averagediameter of the magnetic nanoparticles is in a range of 2 nanometers to20 nanometers. An average thickness of the recording layer is less than0.2 microns.

Illustrative Operating Environment

FIG. 1A illustrates a simplified tape drive 100 of a tape-based datastorage system, which may be employed in the context of the presentinvention. While one specific implementation of a tape drive is shown inFIG. 1A, it should be noted that the approaches described herein may beimplemented in the context of any type of tape drive system.

As shown, a tape supply cartridge 120 and a take-up reel 121 areprovided to support a tape 122. One or more of the reels may form partof a removable cartridge and are not necessarily part of the tape drive100. The tape drive, such as that illustrated in FIG. 1A, may furtherinclude drive motor(s) to drive the tape supply cartridge 120 and thetake-up reel 121 to move the tape 122 over a tape head 126 of any type.Such head may include an array of readers, writers, or both.

Guides 125 guide the tape 122 across the tape head 126. Such tape head126 is in turn coupled to a controller 128 via a cable 130. Thecontroller 128, may be or include a processor and/or any logic forcontrolling any subsystem of the drive 100. For example, the controller128 typically controls head functions such as servo following, datawriting, data reading, etc. The controller 128 may include at least oneservo channel and at least one data channel, each of which include dataflow processing logic configured to process and/or store information tobe written to and/or read from the tape 122. The controller 128 mayoperate under logic known in the art, as well as any logic disclosedherein, and thus may be considered as a processor for any of thedescriptions of tape drives included herein, in various approaches. Thecontroller 128 may be coupled to a memory 136 of any known type, whichmay store instructions executable by the controller 128. Moreover, thecontroller 128 may be configured and/or programmable to perform orcontrol some or all of the methodology presented herein. Thus, thecontroller 128 may be considered to be configured to perform variousoperations by way of logic programmed into one or more chips, modules,and/or blocks; software, firmware, and/or other instructions beingavailable to one or more processors; etc., and combinations thereof.

The cable 130 may include read/write circuits to transmit data to thetape head 126 to be recorded on the tape 122 and to receive data read bythe tape head 126 from the tape 122. An actuator 132 controls positionof the tape head 126 relative to the tape 122.

An interface 134 may also be provided for communication between the tapedrive 100 and a host (internal or external) to send and receive the dataand for controlling the operation of the tape drive 100 andcommunicating the status of the tape drive 100 to the host, all as willbe understood by those of skill in the art.

FIG. 1B illustrates an exemplary tape cartridge 150, which in variousapproaches may include any configuration of the magnetic recording mediadescribed herein in tape form. Such tape cartridge 150 may be used witha system such as that shown in FIG. 1A. As shown, the tape cartridge 150includes a housing 152, a tape 122 in the housing 152, and an optionalnonvolatile memory 156 coupled to the housing 152. In some approaches,the nonvolatile memory 156 may be embedded inside the housing 152, asshown in FIG. 1B. In more approaches, the nonvolatile memory 156 may beattached to the inside or outside of the housing 152 withoutmodification of the housing 152. For example, the nonvolatile memory maybe embedded in a self-adhesive label 154. In one preferred approach, thenonvolatile memory 156 may be solid state memory (e.g., Flash memory),read-only memory (ROM) device, etc., embedded into or coupled to theinside or outside of the tape cartridge 150. The nonvolatile memory isaccessible by the tape drive and the tape operating software (the driversoftware), and/or another device.

By way of example, FIG. 2A illustrates a side view of a flat-lapped,bi-directional, two-module magnetic tape head 200 which may beimplemented in the context of the present invention. As shown, the headincludes a pair of bases 202, each equipped with a module 204, and fixedat a small angle α with respect to each other. The bases may be“U-beams” that are adhesively coupled together. Each module 204 includesa substrate 204A and a closure 204B with a thin film portion, commonlyreferred to as a “gap” in which the readers and/or writers 206 areformed. In use, a tape 208 is moved over the modules 204 along a media(tape) bearing surface 209 in the manner shown for reading and writingdata on the tape 208 using the readers and writers. The wrap angle θ ofthe tape 208 at edges going onto and exiting the flat media supportsurfaces 209 are usually between about 0.1 degree and about 3 degrees.

The substrates 204A are typically constructed of a wear resistantmaterial, such as a ceramic. The closures 204B may be made of the sameor similar ceramic as the substrates 204A.

The readers and writers may be arranged in a piggyback or mergedconfiguration. An illustrative piggybacked configuration comprises a(magnetically inductive) writer transducer on top of (or below) a(magnetically shielded) reader transducer (e.g., a magnetoresistivereader, etc.), wherein the poles of the writer and the shields of thereader are generally separated. An illustrative merged configurationcomprises one reader shield in the same physical layer as one writerpole (hence, “merged”). The readers and writers may also be arranged inan interleaved configuration. Alternatively, each array of channels maybe readers or writers only. Any of these arrays may contain one or moreservo track readers for reading servo data on the medium.

FIG. 2B illustrates the tape bearing surface 209 of one of the modules204 taken from Line 2B of FIG. 2A. A representative tape 208 is shown indashed lines. The module 204 is preferably long enough to be able tosupport the tape as the head steps between data bands.

In this example, the tape 208 includes 4 to 32 data bands, e.g., with 16data bands and 17 servo tracks 210, as shown in FIG. 2B on a one-halfinch wide tape 208. The data bands are defined between servo tracks 210.Each data band may include a number of data tracks, for example 1024data tracks (not shown). During read/write operations, the readersand/or writers 206 are positioned to specific track positions within oneof the data bands. Outer readers, sometimes called servo readers, readthe servo tracks 210. The servo signals are in turn used to keep thereaders and/or writers 206 aligned with a particular set of tracksduring the read/write operations.

FIG. 2C depicts a plurality of readers and/or writers 206 formed in agap 218 on the module 204 in Circle 2C of FIG. 2B. As shown, the arrayof readers and writers 206 includes, for example, 16 writers 214, 16readers 216 and two servo readers 212, though the number of elements mayvary. Illustrative approaches include 8, 16, 32, 40, and 64 activereaders and/or writers 206 per array, and alternatively interleaveddesigns having odd numbers of reader or writers such as 17, 25, 33, etc.An illustrative approach includes 32 readers per array and/or 32 writersper array, where the actual number of transducer elements could begreater, e.g., 33, 34, etc. This allows the tape to travel more slowly,thereby reducing speed-induced tracking and mechanical difficultiesand/or execute fewer “wraps” to fill or read the tape. While the readersand writers may be arranged in a piggyback configuration as shown inFIG. 2C, the readers 216 and writers 214 may also be arranged in aninterleaved configuration. Alternatively, each array of readers and/orwriters 206 may be readers or writers only, and the arrays may containone or more servo readers 212. As noted by considering FIGS. 2A and2B-2C together, each module 204 may include a complementary set ofreaders and/or writers 206 for such things as bi-directional reading andwriting, read-while-write capability, backward compatibility, etc.

FIG. 2D shows a partial tape bearing surface view of complementarymodules of a magnetic tape head 200 according to one approach. In thisapproach, each module has a plurality of read/write (R/W) pairs in apiggyback configuration formed on a common substrate 204A and anoptional electrically insulative insulating layer 236. The writers 214and the readers 216 are aligned parallel to an intended direction oftravel of a tape medium thereacross to form an R/W pair, exemplified byR/W pairs 222. Note that the intended direction of tape travel issometimes referred to herein as the direction of tape travel, and suchterms may be used interchangeably. Such direction of tape travel may beinferred from the design of the system, e.g., by examining the guides;observing the actual direction of tape travel relative to the referencepoint; etc. Moreover, in a system operable for bi-direction readingand/or writing, the direction of tape travel in both directions istypically parallel and thus both directions may be considered equivalentto each other.

Several R/W pairs 222 may be present, such as 8, 16, 32 pairs, etc. TheR/W pairs 222 as shown are linearly aligned in a direction generallyperpendicular to a direction of tape travel thereacross. However, thepairs may also be aligned diagonally, etc. Servo readers 212 arepositioned on the outside of the array of R/W pairs, the function ofwhich is well known.

Generally, the magnetic tape medium moves in either a forward or reversedirection as indicated by arrow 220. The magnetic tape medium and headassembly 200 operate in a transducing relationship in the mannerwell-known in the art. The head assembly 200 includes two thin-filmmodules 224 and 226 of generally identical construction.

Modules 224 and 226 are joined together with a space present betweenclosures 204B thereof (partially shown) to form a single physical unitto provide read-while-write capability by activating the writer of theleading module and reader of the trailing module aligned with the writerof the leading module parallel to the direction of tape travel relativethereto. When a module 224, 226 of a magnetic tape head 200 isconstructed, layers are formed in the gap 218 created above anelectrically conductive substrate 204A (partially shown), e.g., ofAlTiC, in generally the following order for the R/W pairs 222: aninsulating layer 236, a first shield 232 typically of an iron alloy suchas NiFe (−), cobalt zirconium tantalum (CZT) or Al—Fe—Si (Sendust), asensor 234 for sensing a data track on a magnetic medium, a secondshield 238 typically of a nickel-iron alloy (e.g., 80/20 at % NiFe, alsoknown as permalloy), first and second writer poles 228, 230, and a coil(not shown). The sensor may be of any known type, including those basedon magnetoresistive (MR), GMR, AMR, tunneling magnetoresistance (TMR),etc.

The first and second writer poles 228, 230 may be fabricated from highmagnetic moment materials such as ˜45/55 NiFe. Note that these materialsare provided by way of example only, and other materials may be used.Additional layers such as insulation between the shields and/or poletips and an insulation layer surrounding the sensor may be present.Illustrative materials for the insulation include alumina and otheroxides, insulative polymers, etc.

The configuration of the tape head 126 may include multiple module,preferably three or more. In a write-read-write (W-R-W) head, outermodules for writing flank one or more inner modules for reading.Referring to FIG. 3, depicting a W-R-W configuration, the outer modules252, 256 each include one or more arrays of writers 260. The innermodule 254 of FIG. 3 includes one or more arrays of readers 258 in asimilar configuration. Variations of a multi-module head include a R-W-Rhead (FIG. 4), a R-R-W head, a W-W-R head, etc. In yet other variations,one or more of the modules may have read/write pairs of transducers.Moreover, more than three modules may be present. In further approaches,two outer modules may flank two or more inner modules, e.g., in aW-R-R-W, a R-W-W-R arrangement, etc. For simplicity, a W-R-W head isused primarily herein to exemplify aspects of the present invention. Oneskilled in the art apprised with the teachings herein will appreciatehow permutations of the present invention would apply to configurationsother than a W-R-W configuration.

FIG. 5 illustrates a magnetic head 126 according to one approach thatincludes first, second and third modules 302, 304, 306 each having atape bearing surface 308, 310, 312 respectively, which may be flat,contoured, etc. Note that while the term “tape bearing surface” appearsto imply that the surface facing the tape 315 is in physical contactwith the tape bearing surface, this is not necessarily the case. Rather,only a portion of the tape may be in contact with the tape bearingsurface, constantly or intermittently, with other portions of the taperiding (or “flying”) above the tape bearing surface on a layer of air,sometimes referred to as an “air bearing”. The first module 302 will bereferred to as the “leading” module as it is the first moduleencountered by the tape in a three module design for tape moving in theindicated direction. The third module 306 will be referred to as the“trailing” module. The trailing module follows the middle module and isthe last module seen by the tape in a three module design. The leadingand trailing modules 302, 306 are referred to collectively as outermodules. Also note that the outer modules 302, 306 will alternate asleading modules, depending on the direction of travel of the tape 315.

In one approach, the tape bearing surfaces 308, 310, 312 of the first,second and third modules 302, 304, 306 lie on about parallel planes(which is meant to include parallel and nearly parallel planes, e.g.,between parallel and tangential as in FIG. 6), and the tape bearingsurface 310 of the second module 304 is above the tape bearing surfaces308, 312 of the first and third modules 302, 306. As described below,this has the effect of creating the desired wrap angle α₂ of the taperelative to the tape bearing surface 310 of the second module 304.

Where the tape bearing surfaces 308, 310, 312 lie along parallel ornearly parallel yet offset planes, intuitively, the tape should peel offof the tape bearing surface 308 of the leading module 302. However, thevacuum created by a skiving edge 318 of the leading module 302 has beenfound by experimentation to be sufficient to keep the tape adhered tothe tape bearing surface 308 of the leading module 302. A trailing edge320 of the leading module 302 (the end from which the tape leaves theleading module 302) is the approximate reference point which defines thewrap angle α₂ over the tape bearing surface 310 of the second module304. The tape stays in close proximity to the tape bearing surface untilclose to the trailing edge 320 of the leading module 302. Accordingly,transducers 322 may be located near the trailing edges of the outermodules 302, 306. These approaches are particularly adapted forwrite-read-write applications.

A benefit of this and other aspects described herein is that, becausethe outer modules 302, 306 are fixed at a determined offset from thesecond module 304, the inner wrap angle α₂ is fixed when the modules302, 304, 306 are coupled together or are otherwise fixed into a head.The inner wrap angle α₂ is approximately tan⁻¹(δ/W) where δ is theheight difference between the planes of the tape bearing surfaces 308,310 and W is the width between the opposing ends of the tape bearingsurfaces 308, 310. An illustrative inner wrap angle α₂ is in a range ofabout 0.3° to about 1.1°, though can be any angle required by thedesign.

Beneficially, the inner wrap angle α₂ on the side of the module 304receiving the tape (leading edge) will be larger than the inner wrapangle α₃ on the trailing edge, as the tape 315 rides above the trailingmodule 306. This difference is generally beneficial as a smaller α₃tends to oppose what has heretofore been a steeper exiting effectivewrap angle.

Note that the tape bearing surfaces 308, 312 of the outer modules 302,306 are positioned to achieve a negative wrap angle at the trailing edge320 of the leading module 302. This is generally beneficial in helpingto reduce friction due to contact with the trailing edge 320, providedthat proper consideration is given to the location of the crowbar regionthat forms in the tape where it peels off the head. This negative wrapangle also reduces flutter and scrubbing damage to the elements on theleading module 302. Further, at the trailing module 306, the tape 315flies over the tape bearing surface 312 so there is virtually no wear onthe elements when tape is moving in this direction. Particularly, thetape 315 entrains air and so will not significantly ride on the tapebearing surface 312 of the third module 306 (some contact may occur).This is permissible, because the leading module 302 is writing while thetrailing module 306 is idle.

Writing and reading functions are performed by different modules at anygiven time. In one approach, the second module 304 includes a pluralityof data and optional servo readers 331 and no writers. The first andthird modules 302, 306 include a plurality of writers 322 and no datareaders, with the exception that the outer modules 302, 306 may includeoptional servo readers. The servo readers may be used to position thehead during reading and/or writing operations. The servo reader(s) oneach module are typically located towards the end of the array ofreaders or writers.

By having only readers or side by side writers and servo readers in thegap between the substrate and closure, the gap length can besubstantially reduced. Typical heads have piggybacked readers andwriters, where the writer is formed above each reader. A typical gap is20-35 microns. However, irregularities on the tape may tend to droopinto the gap and create gap erosion. Thus, the smaller the gap is thebetter. The smaller gap enabled herein exhibits fewer wear relatedproblems.

In some approaches, the second module 304 has a closure, while the firstand third modules 302, 306 do not have a closure. Where there is noclosure, preferably a hard coating is added to the module. One preferredcoating is diamond-like carbon (DLC).

In the approach shown in FIG. 5, the first, second, and third modules302, 304, 306 each have a closure 332, 334, 336, which extends the tapebearing surface of the associated module, thereby effectivelypositioning the read/write elements away from the edge of the tapebearing surface. The closure 332 on the second module 304 can be aceramic closure of a type typically found on tape heads. The closures334, 336 of the first and third modules 302, 306, however, may beshorter than the closure 332 of the second module 304 as measuredparallel to a direction of tape travel over the respective module. Thisenables positioning the modules closer together. One way to produceshorter closures 334, 336 is to lap the standard ceramic closures of thesecond module 304 an additional amount. Another way is to plate ordeposit thin film closures above the elements during thin filmprocessing. For example, a thin film closure of a hard material such asSendust or nickel-iron alloy (e.g., 45/55) can be formed on the module.

With reduced-thickness ceramic or thin film closures 334, 336 or noclosures on the outer modules 302, 306, the write-to-read gap spacingcan be reduced to less than about 1 mm, e.g., about 0.75 mm, or 50% lessthan commonly-used linear tape open (LTO) tape head spacing. The openspace between the modules 302, 304, 306 can still be set toapproximately 0.5 to 0.6 mm, which in some approaches is ideal forstabilizing tape motion over the second module 304.

Depending on tape tension and stiffness, it may be desirable to anglethe tape bearing surfaces of the outer modules relative to the tapebearing surface of the second module. FIG. 6 illustrates an apparatuswhere the modules 302, 304, 306 are in a tangent or nearly tangent(angled) configuration. Particularly, the tape bearing surfaces of theouter modules 302, 306 are about parallel to the tape at the desiredwrap angle α₂ of the second module 304. In other words, the planes ofthe tape bearing surfaces 308, 312 of the outer modules 302, 306 areoriented at about the desired wrap angle α₂ of the tape 315 relative tothe second module 304. The tape will also pop off of the trailing module306 in this approach, thereby reducing wear on the elements in thetrailing module 306. These approaches are particularly useful forwrite-read-write applications. Additional aspects of these approachesare similar to those given above.

Typically, the tape wrap angles may be set about midway between theapproaches shown in FIGS. 5 and 6.

FIG. 7 illustrates an apparatus where the modules 302, 304, 306 are inan overwrap configuration. Particularly, the tape bearing surfaces 308,312 of the outer modules 302, 306 are angled slightly more than the tape315 when set at the desired wrap angle α₂ relative to the second module304. In this approach, the tape does not pop off of the trailing module,allowing it to be used for writing or reading. Accordingly, the leadingand middle modules can both perform reading and/or writing functionswhile the trailing module can read any just-written data. Thus, theseapproaches are preferred for write-read-write, read-write-read, andwrite-write-read applications. In the latter approaches, closures shouldbe wider than the tape canopies for ensuring read capability. The widerclosures may require a wider gap-to-gap separation. Therefore, apreferred approach has a write-read-write configuration, which may useshortened closures that thus allow closer gap-to-gap separation.

Additional aspects of the approaches shown in FIGS. 6 and 7 are similarto those given above.

A 32 channel version of a multi-module tape head 126 may use cables 350having leads on the same or smaller pitch as current 16 channelpiggyback LTO modules, or alternatively the connections on the modulemay be organ-keyboarded for a 50% reduction in cable span. Over-under,writing pair unshielded cables may be used for the writers, which mayhave integrated servo readers.

The outer wrap angles α₁ may be set in the drive, such as by guides ofany type known in the art, such as adjustable rollers, slides, etc. oralternatively by outriggers, which are integral to the head. Forexample, rollers having an offset axis may be used to set the wrapangles. The offset axis creates an orbital arc of rotation, allowingprecise alignment of the wrap angle α₁.

To assemble any of the approaches described above, conventional u-beamassembly can be used. Accordingly, the mass of the resultant head may bemaintained or even reduced relative to heads of previous generations. Inother approaches, the modules may be constructed as a unitary body.Those skilled in the art, armed with the present teachings, willappreciate that other known methods of manufacturing such heads may beadapted for use in constructing such heads. Moreover, unless otherwisespecified, processes and materials of types known in the art may beadapted for use in various approaches in conformance with the teachingsherein, as would become apparent to one skilled in the art upon readingthe present disclosure.

As a tape is run over a module, it is preferred that the tape passessufficiently close to magnetic transducers on the module such thatreading and/or writing is efficiently performed, e.g., with a low errorrate. According to some approaches, tape tenting may be used to ensurethe tape passes sufficiently close to the portion of the module havingthe magnetic transducers. To better understand this process, FIGS. 8A-8Cillustrate the principles of tape tenting. FIG. 8A shows a module 800having an upper tape bearing surface 802 extending between oppositeedges 804, 806. A stationary tape 808 is shown wrapping around the edges804, 806. As shown, the bending stiffness of the tape 808 lifts the tapeoff of the tape bearing surface 802. Tape tension tends to flatten thetape profile, as shown in FIG. 8A. Where tape tension is minimal, thecurvature of the tape is more parabolic than shown.

FIG. 8B depicts the tape 808 in motion. The leading edge, i.e., thefirst edge the tape encounters when moving, may serve to skive air fromthe tape, thereby creating a subambient air pressure between the tape808 and the tape bearing surface 802. In FIG. 8B, the leading edge isthe left edge and the right edge is the trailing edge when the tape ismoving left to right. As a result, atmospheric pressure above the tapeurges the tape toward the tape bearing surface 802, thereby creatingtape tenting proximate each of the edges. The tape bending stiffnessresists the effect of the atmospheric pressure, thereby causing the tapetenting proximate both the leading and trailing edges. Modeling predictsthat the two tents are very similar in shape.

FIG. 8C depicts how the subambient pressure urges the tape 808 towardthe tape bearing surface 802 even when a trailing guide 810 ispositioned above the plane of the tape bearing surface.

It follows that tape tenting may be used to direct the path of a tape asit passes over a module. As previously mentioned, tape tenting may beused to ensure the tape passes sufficiently close to the portion of themodule having the magnetic transducers, preferably such that readingand/or writing is efficiently performed, e.g., with a low error rate.

Magnetic tapes may be stored in tape cartridges that are, in turn,stored at storage slots or the like inside a data storage library. Thetape cartridges may be stored in the library such that they areaccessible for physical retrieval. In addition to magnetic tapes andtape cartridges, data storage libraries may include data storage drivesthat store data to, and/or retrieve data from, the magnetic tapes.Moreover, tape libraries and the components included therein mayimplement a file system which enables access to tape and data stored onthe tape.

File systems may be used to control how data is stored in, and retrievedfrom, memory. Thus, a file system may include the processes and datastructures that an operating system uses to keep track of files inmemory, e.g., the way the files are organized in memory. Linear TapeFile System (LTFS) is an exemplary format of a file system that may beimplemented in a given library in order to enables access to complianttapes. It should be appreciated that various aspects described hereincan be implemented with a wide range of file system formats, includingfor example IBM Spectrum Archive Library Edition (LTFS LE). However, toprovide a context, and solely to assist the reader, some of theapproaches below may be described with reference to LTFS which is a typeof file system format. This has been done by way of example only, andshould not be deemed limiting on the invention defined in the claims.

A tape cartridge may be “loaded” by inserting the cartridge into thetape drive, and the tape cartridge may be “unloaded” by removing thetape cartridge from the tape drive. Once loaded in a tape drive, thetape in the cartridge may be “threaded” through the drive by physicallypulling the tape (the magnetic recording portion) from the tapecartridge, and passing it above a magnetic head of a tape drive.Furthermore, the tape may be attached on a take-up reel (e.g., see 121of FIG. 1A above) to move the tape over the magnetic head.

Once threaded in the tape drive, the tape in the cartridge may be“mounted” by reading metadata on a tape and bringing the tape into astate where the LTFS is able to use the tape as a constituent componentof a file system. Moreover, in order to “unmount” a tape, metadata ispreferably first written on the tape (e.g., as an index), after whichthe tape may be removed from the state where the LTFS is allowed to usethe tape as a constituent component of a file system. Finally, to“unthread” the tape, the tape is unattached from the take-up reel and isphysically placed back into the inside of a tape cartridge again. Thecartridge may remain loaded in the tape drive even after the tape hasbeen unthreaded, e.g., waiting for another read and/or write request.However, in other instances, the tape cartridge may be unloaded from thetape drive upon the tape being unthreaded, e.g., as described above.

Magnetic tape is a sequential access medium. Thus, new data is writtento the tape by appending the data at the end of previously written data.It follows that when data is recorded in a tape having only onepartition, metadata (e.g., allocation information) is continuouslyappended to an end of the previously written data as it frequentlyupdates and is accordingly rewritten to tape. As a result, the rearmostinformation is read when a tape is first mounted in order to access themost recent copy of the metadata corresponding to the tape. However,this introduces a considerable amount of delay in the process ofmounting a given tape.

To overcome this delay caused by single partition tape mediums, the LTFSformat includes a tape that is divided into two partitions, whichinclude an index partition and a data partition. The index partition maybe configured to record metadata (meta information), e.g., such as fileallocation information (Index), while the data partition may beconfigured to record the body of the data, e.g., the data itself.

Looking to FIG. 9, a magnetic tape 900 having an index partition 902 anda data partition 904 is illustrated according to one approach. As shown,data files and indexes are stored on the tape. The LTFS format allowsfor index information to be recorded in the index partition 902 at thebeginning of tape 906, as would be appreciated by one skilled in the artupon reading the present description.

As index information is updated, it preferably overwrites the previousversion of the index information, thereby allowing the currently updatedindex information to be accessible at the beginning of tape in the indexpartition. According to the specific example illustrated in FIG. 9, amost recent version of metadata Index 3 is recorded in the indexpartition 902 at the beginning of the tape 906. Conversely, all threeversion of metadata Index 1, Index 2, Index 3 as well as data File A,File B, File C, File D are recorded in the data partition 904 of thetape. Although Index 1 and Index 2 are old (e.g., outdated) indexes,because information is written to tape by appending it to the end of thepreviously written data as described above, these old indexes Index 1,Index 2 remain stored on the tape 900 in the data partition 904 withoutbeing overwritten.

The metadata may be updated in the index partition 902 and/or the datapartition 904 the same or differently depending on the desired approach.According to some approaches, the metadata of the index and/or datapartitions 902, 904 may be updated in response to the tape beingunmounted, e.g., such that the index may be read quickly from the indexpartition when that tape is mounted again. The metadata is preferablyalso written in the data partition 904 so the tape may be mounted usingthe metadata recorded in the data partition 904, e.g., as a backupoption.

According to one example, which is no way intended to limit theinvention, LTFS LE may be used to provide the functionality of writingan index in the data partition when a user explicitly instructs thesystem to do so, or at a time designated by a predetermined period whichmay be set by the user, e.g., such that data loss in the event of suddenpower stoppage can be mitigated.

Magnetic Recording Media and Fabrication of Layers Thereof

FIG. 10 depicts a partial cross-sectional view of the basic structure ofa magnetic recording medium 1000, not to scale, in accordance withvarious approaches described herein. As an option, the present magneticrecording medium 1000 may be implemented in conjunction with featuresfrom any other approach listed herein, such as those described withreference to the other FIGS. Of course, however, such magnetic recordingmedium 1000 and others presented herein may be used in variousapplications and/or in permutations which may or may not be specificallydescribed in the illustrative approaches listed herein. Further, themagnetic recording medium 1000 presented herein may be used in anydesired environment. The magnetic recording medium 1000 in variouspermutations disclosed herein was developed to improve the stability andperformance of tape storage media over the required environments for useand storage.

Except as otherwise described herein, the various layers of the magneticrecording medium 1000 may be of conventional construction, design and/orfunction. In various approaches, a new and novel layer may be used withconventional layers. In further approaches, multiple new and novellayers may be used together with other conventional layers.

Except as otherwise described herein, the various layers of the magneticrecording medium 1000 may be formed using conventional methods,especially where the respective layer is of conventional construction.

The magnetic recording medium 1000 is preferably a magnetic recordingtape, but in other aspects is a different type of deformable media.

As shown in FIG. 10, four basic layers are present in the magneticrecording medium 1000. An optional backcoat 1002 is positioned along oneside (lower side in the FIG.) of a substrate 1004. An underlayer 1006 ispositioned along another side (upper side in the FIG.) of the substrate1004. A recording layer 1008 is positioned above the underlayer 1006.Additional layers of conventional construction may be present in themagnetic recording medium 1000, in various approaches. For example, thebackcoat may be eliminated and multiple layers deposited on both sidesof the substrate to allow recording on both sides of the final tape.

Backcoat

The backcoat 1002 may or may not be present in the magnetic recordingmedium 1000. The backcoat 1002 may be of conventional construction,design and function, and in some approaches may have a conventionalcomposition including a conductive carbon black dispersed in a polymerbinder system as commonly practiced in the industry for decades, though,again, any conventional backcoat material may be used. Preferably, thebackcoat 1002 is constructed of a material that provides one or more ofthe following benefits: facilitate separation from another section ofthe tape would thereover on a spool, tribology improvement, dissipationof static electricity, etc. A preferred thickness of the backcoat 1002is less than about 0.3 microns, preferably less than about 0.2 microns.

Substrate

The substrate 1004 is preferably of conventional construction, designand function. The substrate 1004 is typically the thickest layer.Illustrative materials for the substrate 1004 include polyethyleneterephthalate (polyester or PET), polyethylene naphthalate (PEN),super-tensilised PEN, an aramid-like material (e.g., solubilizedpara-imide such as one sold under the trade name Mictron™ sold by TorayIndustries, Inc. having a place of business at Nihonbashi Mitsui Tower,1-1, Nihonbashi-Muromachi, 2-chrome, Chuo-ku, Tokyo 103-8666, Japan),etc.

Underlayer

The underlayer 1006 provides one or more of the following functions inthe structure: attenuation of magnetic signal passing through therecording layer, adhesion of the recording layer to the substrate 1004,etc. Accordingly, in most approaches described herein, the function ofthe underlayer 1006 is not to retain any memory of the writer flux, butrather to improve the write flux box coming from the write head elementduring writing to the recording layer 1008. Moreover, any retainedmagnetic moment orientation from writing is preferably weak ornon-existent so as to minimize noise during readback.

One very important attribute of the magnetic filled coating in theunderlayer, according to various approaches, is to quickly absorb thestray field passing through the recording layer above during the veryrapid magnetic switching encountered during writing. The idealunderlayer should have a very low remnant moment (M_(r)) so that itretains no orientation after the write field passes through that volumeof the underlayer.

In some approaches, the underlayer 1006 is of new and novelconstruction. The new and novel underlayer 1006 may be present in themedium 1000 with a conventional recording layer 1008 there above, in oneaspect. In another aspect, the new and novel underlayer 1006 may bepresent in the medium 1000 with a new and novel recording layer 1008there above. In other approaches, the underlayer 1006 is of conventionalconstruction, and is present in the medium 1000 with a new and novelrecording layer 1008 there above.

In various approaches, the underlayer 1006 has one or more of thefollowing characteristics, and preferably all of the followingcharacteristics: electrically conductive, weakly magnetic (a bulkmagnetic strength in Oersted (Oe) that is less than 200 Oe, andpreferably less than 100 Oe. Ideally, the underlayer is coated andcalendared prior to formation of the recording layer 1008 thereon toimprove the recording layer 1008 interface, as described in more detailbelow. In a preferred embodiment, the underlayer 1006 has about onetenth the coercivity in Oersteds) of the recording layer 1008 and lowremnant magnetization enabling the underlayer 1006 to act as a magneticfield flux absorber without creating signal interference with therecording layer 1008 above it.

The electrically conductive characteristic is operative to reducecorrosion of magnetic heads operating on a tape. Particularly, when atape is unwound, the separation between the recording layer generates atriboelectric potential and current, which in a dry environment canproduce a static discharge, and in a humid environment produce anelectro-chemical pathway for head corrosion. Both of these situationsare undesirable for tape performance and durability, both believed to bea significant factor in head corrosion. The electrically conductivecharacteristic of the underlayer 1006 assists in dissipating the charge,e.g., by transporting the charge to a hub coupled to a ground, therebyminimizing charge traveling into the head and consequently lessening therisk of condensed liquid water forming a conductive path between thetape and head surface that provides a path for the electrochemicalcorrosion of the recording head structures.

The weakly magnetic characteristic reduces the amount of noisecontributed by the magnetic fields emanating from the underlayer 1006and improves the resolution of the written bits in the recording layerabove the underlayer.

In approaches where the underlayer 1006 is of conventional constructionand typically utilizes low coercivity and low moment particles in themicron size range. The coating is not optimized for a high loading ofvery small (nano scale) particles. The underlayer in some approaches isconstructed with a weakly magnetic iron oxide using a conventionalpolyester-polyurethane rubbery resin with a poly(vinyl acetate-vinylalcohol-vinyl chloride) hard resin cured with a poly(isocyanate) as usedin earlier tape product formats. However, such conventional coatingswere not specifically designed or formulated to be an optimum underlayerfor the signal recording layer above it in the final tape.

In preferred approaches, the underlayer 1006 includes a new formulationin which the underlayer 1006 includes particles 1010 which are weaklymagnetic but are also electrically conductive and dispersed in alow-stress UV-cured matrix providing good adhesion to the substrate andproviding mechanical stability and stress relief to the very thinrecording layer above it.

The underlayer 1006 does not need to have a narrow distribution ofnanoparticle sizes, in various approaches, though use of small particlesimproves the surface roughness presented to the recording layer when therecording layer is being applied. Using the novel fabrication processesdescribed herein, the underlayer 1006 is not attacked (swollen by therecording layer during application of the recording layer thereon).

In preferred approaches, the underlayer 1006 includes a new formulationin which the underlayer 1006 includes encapsulated nanoparticles 1010each comprising at least one magnetic nanoparticle 1012, and preferablyonly one magnetic nanoparticle 1012, encapsulated by an aromatic polymer1014. A polymeric binder 1016 binds the encapsulated nanoparticles inthe underlayer 1006.

An average concentration of the encapsulated nanoparticles in theunderlayer 1006 is preferably at least about 35 vol %, e.g., 40 vol %,45 vol %, 50 vol %, 55 vol %, 60 vol %, greater than about 60 vol %, ina range of about 40-75 vol %, in a range of about 45-75 vol %, in arange of about 50-75 vol %, in a range of about 35-50 vol %, in a rangeof about 40-60 vol %, or any other sub-range within the aforementionedranges. Ideally, the average concentration of the encapsulatednanoparticles does not exceed the critical pigment volume concentration(CPVC) at which the coating would lose its mechanical integrity and nolonger function as a viable, durable coating. For nanoparticle filledcoatings, a very high surface area can reduce the CPVC dramaticallyunless a novel encapsulation of the nanoparticles and binder design isimplemented to allow a higher CPVC. The CPVC may be determined usingDynamic Mechanical Analysis (DMA) of free films of the coating for aseries of coatings with increasing vol % of the filler. Conventional DMAtechniques may be used on the novel formulations described herein. TheCPVC is determined at the vol % at which the tensile storage modulus(E′) reaches its maximum value. FIG. 11 depicts a CPVC DMA plot 1100 forvarious vol % of pigment in an underlayer, according to variousapproaches. Such plot 1100 is exemplary of plot(s) which may begenerated by one skilled in the art following the teachings herein andusing conventional DMA plotting techniques, and without resorting toundue experimentation.

The magnetic nanoparticles preferably include a weakly ferrimagneticmaterial. By “weakly ferrimagnetic” what is meant is that the magneticnanoparticles do not have a high coercivity (H_(c)) or magnetic moment(M_(r)), but rather have an average magnetic field strength thatcontributes a minimal signal during reading of the overlaying recordinglayer. The final coating ideally presents no detectable noise signalcontribution to the observed response for the written bits in the datastorage layer.

In preferred approaches, the magnetic nanoparticles have a coercivity(H_(c)) of less than about 200 Oe, more preferably less than 100 Oe, andgreater than 50 Oe. An exemplary range of the field strength of themagnetic nanoparticles is 50-200 Oe. The magnetic nanoparticles are alsopreferably characterized by a low remnant moment, e.g., <12 emu/g.

A preferred material for the magnetic nanoparticles is a chromiumdioxide, which is weakly magnetic, electrically conductive, and veryhard. In other approaches, the magnetic nanoparticles include one ormore of: magnetic metal particles having an oxidized outer surface oroxide thereon (at the cost of conductivity) such as cobalt, nickel oriron, and alloys thereof.

An average diameter of the magnetic nanoparticles is preferably in arange of 2 nanometers (nm) to 20 nm, more preferably 4 nm to 10 nm,depending on the material, though the average diameter could be higheror lower than this range in some approaches. One consideration aboutaverage diameter is that the smaller the size, the harder it may be forthe binder to properly hold the pigments in the coating matrix.Accordingly, the average diameter of the magnetic nanoparticles shouldbe selected to maintain the critical pigment volume in an acceptablerange. If the average diameter is too small, insufficient binder may bepresent between adjacent particles, making the material brittle andsusceptible to breakage. If the particles are too large, the interfacebetween the underlayer 1006 and recording layer 1008 loses the desiredsmooth characteristic described herein.

In preferred approaches, the magnetic nanoparticles present in theunderlayer are weakly magnetic and electrically conductive and areformulated to produce a dried coating with negligible or no swelling bythe solvent used to apply the recording layer. The use of nanoparticlesin the underlayer is preferred to use of larger particles so as to allowa smoother interface with the recording layer.

The encapsulated nanoparticles in various preferred implementations mayhave a broad size distribution so long as the resulting dried film doesnot exceed the critical pigment volume concentration.

Preferably, the majority of the particles in the underlayer 1006 arecoated with sufficient binder so as to achieve a cohesive and stablecoating with a minimal number of coated clusters of particles oraggregates. The ideal coating would have no clusters or aggregates inthe final coating such that close to 100% of the particles arecompletely dispersed in the binder matrix as individual particles. Gooddispersion of the particles into the matrix with minimal orientation ofthe particles further reduces the noise contribution of the underlayerto the recorded signal in the recording layer.

Also preferably, the encapsulated nanoparticles are not well alignedwith each other, e.g., are randomly oriented in the underlayer 1006.This further improves the performance of the underlayer by reducingformation of ordered magnetic regions within the underlayer 1006 whichreduces the noise produced in the underlayer 1006. Nonetheless, while itis desirable to generate a monodisperse non-aggregated dispersion ofencapsulated particles for the coating preparation, this is notnecessary for the underlayer, since the mechanical properties are moreimportant than magnetic signal performance.

The aromatic polymer encapsulating the magnetic nanoparticles may beand/or include any of many different aromatic polymers, as long as thearomatic polymer encapsulates at least about 80% of the surface of themagnetic nanoparticle, preferably at least about 90% of the surface ofthe magnetic nanoparticle, and ideally approximately 100% of themagnetic nanoparticle in the underlayer 1006. Accordingly, the aromaticpolymer forms at least a partial shell, and preferably a full shell,around the magnetic nanoparticles.

The layer encapsulating the nanoparticles can be as thin as a molecularmonolayer, e.g., less than 0.4 nm, but a more robust layer is achievedat about 1-2 nm thick. As the layer becomes thicker the packing of thenanoparticles into the coating decreases. This is not as critical in theunderlayer as it is in the recording layer.

An average thickness of the aromatic polymer encapsulating the magneticnanoparticles is preferably in a range of about 0.5 nm to about 8 nm,e.g., 1-4 nm, 3-5 nm, 4-5 nm, 4-7 nm, 5-7 nm, etc. but could be slightlyhigher or lower than these ranges. Thicknesses used herein generallyrefer to deposition thickness on the underlying structure, unlessotherwise noted.

Aromatic polymers are preferred as the encapsulating layer, because thearomatic ring structure(s) that encapsulates the surface of the magneticnanoparticle. Aromatic rings have a very beneficial behavior,particularly with chemically reactive metal oxides such as chromiumoxide, due to the unique characteristic of aromaticity in such moleculeswhich offers improved stability and some magnetic shielding at thesurface of the magnetic nanoparticles if properly aligned with themagnetic axes of the magnetic nanoparticles. For example, the aromaticring structures can act as a magnetic field modifier due to their uniquemolecular electronic structure and ability to moderate an externalmagnetic field.

Aromatic polymers also provide magnetic shielding at the surface of thepigment, and help isolate the magnetic nanoparticles from otherparticles to improve the independent switching of the encapsulatednanoparticles, resulting in higher bit resolution.

A preferred aromatic polymer is a carbamate. A preferred example of anaromatic molecule known to react with chromium dioxide particles toeffectively encapsulate and isolate the particles from its neighbors ina close packed matrix is methylene bis diphenyl carbamate. Ideally, theencapsulating polymer is constructed from methylene bis diphenylcarbamate with a functional acrylic polyester as the ester segment forthe aromatic carbamate when used with nanoparticles of chromium dioxide.Upon UV irradiation, polymerization on the surface of the particle canproceed to form the encapsulating polymer film layer.

For use with chromium dioxide magnetic nanoparticles in particular, thearomatic polymer is preferably an aliphatic substituted aromatic, e.g.,having an oxidizable portion that reacts with chromium, therebyassisting in adsorption of the aromatic polymer to the chromium dioxidemicroparticle. The benzylic carbon of the diphenyl methane dicarbamateis known to be oxidized efficiently by chromium dioxide to tightly bindthe resulting diphenyl ketone to the particle surface.

In other approaches, the aromatic polymer includes reactive functionalsubstituent such as amines, alcohols, carboxylic acids or nitrilegroups. An example is cinnamic which is present as a copolymer withstyrene to form a bound polymer layer on the nanoparticle surface.

In yet other approaches, the aromatic polymer includes one or morerepeating units with substituents capable of chemical adsorption and/orbonding to the particle surface such as amines, a carboxylic acid suchas cinnamic acid, and other functional aromatics that will bind with thesurface of the magnetic nanoparticle being used.

In an alternative implementation, the encapsulating layer of theencapsulated microparticles is not of a fully aromatic polymer but maybe a copolymer such as a polyester polyurethane or acrylic modifiedpolyurethane. Examples include aliphatic polymers of known type,non-aromatic polymers of known type, etc.

The polymeric binder binding the encapsulated nanoparticles together maybe and/or include various types of binder material. In preferredapproaches, the binder includes an acrylic polymer, e.g., a polymer ofacrylic acid or an acrylate, and preferably a functional acrylicpolymer. Illustrative acrylic polymers suitable for use as a binder invarious approaches include components such as methyl methacrylate,acrylic acid, and others. In general, preferred polymeric binders arethose with a number average molecular weight of less than about 2400,and preferably less than about 1200.

In a preferred implementation, the polymeric binder has UV curablefunctionality to enable binding to the encapsulating layer of theencapsulated microparticles. This functionality can be provided byacrylate groups, vinyl, etc.

In some approaches, the binder includes a vinyl chloride, vinylacetate-vinyl alcohol copolymers. In yet other approaches, the binderincludes polyester or polyether polyurethanes. For the nanoparticlefilled coatings the polymers will be much lower molecular weight (size)than previously employed materials. Typically, the useful polymers areless than 20 repeat units in length prior to UV cure.

The relative amounts of encapsulated nanoparticles to binder in theunderlayer 1006 should be in a range that is not above the criticalpigment volume concentration (CPVC). One skilled in the art, once armedwith the novel formulations described herein, would be able to calculatethe CPVC using known techniques based on the characteristics of thematerials used, such as binder used, particle surface area, etc. Ageneral rule of thumb is less than about 50 vol % pigment (encapsulatednanoparticles) in the underlayer 1006, so that structural integrity ofthe underlayer 1006 is maintained, along with other functions of theunderlayer 1006 such as structurally stabilizing the magnetic layer,enhancing durability of the tape, and providing adhesion of therecording layer 1008. The pigment loading is preferably high enough toprovide adequate mechanical integrity as measured with DMA willpreserving enough electrical conductivity to mitigate undesirabletriboelectric properties.

Additional materials may be present in the underlayer 1006, such asmobile lubricants and/or stabilizers used for dispersion stabilizationprior to application and cure.

The resulting underlayer 1006 is preferably characterized by a weaklymagnetic, electrically conductive, encapsulated nanoparticle dispersionin a tightly bound binder to the pigment (encapsulated nanoparticles) soas to achieve a dried coating with an onset glass transition temperatureTg in the Tensile Storage Modulus (E′) vs. temperature plot from 0°centigrade (C) to 60° C. The Tg should be higher than 35° C., preferablyin excess of about 45° C., and an absolute value for E′ measured at 10Hz via DMA at 20° C. of at least about 6 gigapascals (GPa) up to about16 GPa or slightly higher, e.g., about 8 GPa, about 10 GPa, about 11GPa, 12 GPa, about 15 GPa, about 16 GPa. The normal operating range fortape, in most approaches, is in the range of 0° C. to 60° C., but couldbe higher or lower.

Binders used in conventional magnetic recording tapes result in anunderlayer 1006 having a glass transition temperature of 20-30° C. Thisis too soft, resulting in the underlayer 1006 being too pliable duringuse to provide a stable and consistent recording medium. However, theunderlayer 1006 should be sufficiently elastic to remain tough anddurable during use and storage. Accordingly, preferred embodimentsresult in an underlayer 1006 that has an onset Tg as determined by a DMAplot of the E′ vs temperature in excess of about 35° C., with thepreferred onset Tg of a very broad response that remains in the elasticregime at 10 Hz to at least 50° C.

An average thickness of the underlayer 1006 is less than 1 micron andpreferably less than about 0.6 microns. Lower thicknesses are preferredto allow more tape to be wound into the fixed volume of a given tapecartridge.

In preferred approaches, no wear particles are present in the underlayer1006, and ideally, no wear particles are present in the product at all.Wear particles, conventionally added for purposes of cleaning the tapehead and/or reducing stiction, have been found to constitute anincreasingly intolerable defect and source of damage to the shrinkingread and write structures in current and future recording heads.However, in other approaches, wear particles may be present in theunderlayer 1006.

The underlayer 1006 is preferably applied to the substrate 1004, atleast partially dried, and cured prior to application of the magneticrecording layer 1008 to minimize interlayer turbidity. Accordingly, inpreferred approaches, the recording layer 1008 is substantially notintermixed with the underlayer 1006 (and vice versa). This featureovercomes a longstanding problem in magnetic recording tape products.

Referring to FIG. 12, there is shown a TEM image of a cross section of aconventional recording tape 1200. As shown, the interface between therecording layer and the underlying underlayer is clearly defined. Thelight particles in the recording layer are barium ferrite particles. Asshown, the barium ferrite particles are not monodisperse, nortight-packed in the recording layer. Moreover, voids are present wherethere are no particles. In addition, the interface between the recordinglayer and underlayer is quite rough. Ideally, magnetic fields would passfrom a writer perfectly perpendicular through the recording layer.Unfortunately, magnetic fields expand, or curve, upon leaving writer,with the curvature being more pronounced the farther it is from the poletip of the writer. The voids, undulating interface between the recordinglayer and underlayer, and nonuniform dispersion of the magneticparticles all compound the effects of the expanding writer field. Wherea transition is written (e.g., write field directed down, then up as thetape moves past the writer), and the field is expanding, say 10-20% asit passes through the recording layer, the transition is not sharp,reducing the resolution of the tape. During readback, the transition isnoisy because it is not sharp. A 1 dB improvement in the signal to noiseratio (SNR) during readback is a significant achievement. The inventorbelieves an improvement of up to 5 or 6 dB in the signal to noise ratio(SNR) during readback can be achieved using the new and novel recordinglayer described herein formed upon a cured underlayer whereby interlayerturbidity is minimized.

In preferred approaches, the upper surface of the underlayer issubstantially flat, with a modulation of less than about 25% of thethickness of the interfacial boundary as imaged in the TEM cross sectionof the final tape coating, preferably less than about 5%, e.g., like theupper surface of the recording layer shown in FIG. 12.

Process for Fabricating Underlayer

A method for fabricating the underlayer 1006, e.g., of a magneticrecording medium, in accordance with various approaches, is presentedbelow. As an option, the present method may be implemented to fabricateunderlayers 1006 such as those described above. Of course, however, thismethod and others presented herein may be used to form underlayers 1006which may or may not be related to the illustrative aspects listedherein. Further, the methods presented herein may be carried out in anydesired environment. Moreover, more or less operations than thosedescribed below may be included in the method, according to variousapproaches. It should also be noted that any of the aforementionedfeatures may be used in any of the approaches described in accordancewith the various methods.

The method generally includes forming an underlayer 1006 that hasencapsulated nanoparticles each comprising at least one magneticnanoparticle encapsulated by an aromatic polymer, and a polymeric binderbinding the encapsulated nanoparticles.

Encapsulated nanoparticles may be purchased, or fabricated. For example,in some approaches, commercially available encapsulated nanoparticlesusable for medical imaging and drug delivery applications may be used.

In one approach, forming the underlayer 1006 includes mixing thepolymeric binder with the encapsulated nanoparticles and a solvent(solvent system) to form a mixture. The relative amounts of encapsulatednanoparticles and binder are preferably selected to providecharacteristics listed in the previous section. For example, the mixingincludes ultrasonically dispersing the encapsulated nanoparticles intothe polymeric binder and solvent, thereby creating a radiation-curableemulsion in the solvent.

Conventional coating methods would require formulation to achieve auseful viscosity and likely require much higher molecule weight bindersthan would be optimal for the target design for the present advancedtape construction. As a result, what are described herein are examplesof formulations not suitable for conventional coating. All of theexamples are best applied to the substrate as a sprayed-on aerosolcoating, though other coating methods are contemplated.

In general, the solvent used herein should provide one or more, andpreferably all, of the following characteristics: the solvent causes thepolymeric binder to swell, but allows the polymers to collapse aroundthe pigment rather than shrinking during drying. The solvent causes thechain of the polymeric binder to uncoil and move toward its thetacondition (minimum free volume).

The layer is most stable when the polymeric binder is in thetacondition, and it is at this point where the curing should occur. UVcuring is preferred when the polymeric binder is close to its thetacondition due to the speed at which curing occurs.

One of the solvent components should be a good solvent for the binderadditive, and helps suspend the polymer encapsulated magnetic particles.The second solvent may be a non-solvent for the polymeric binder. As the‘good’ solvent phase evaporates, the remaining coating moves closer to anon-solvent dominated coalescing coating. The second solvent-richcoating thus passes through a point in the drying process in which thebinder and encapsulated magnetic particles are about at their minimumfree volume or theta conditions. This produces a minimal residual stressin the final, dried coating. This in turn eliminates curl and cupping inthe final tape.

A preferred solvent is a water and tetrahydrofuran (THF) solvent systemin relative concentrations that render the solvent system almostcompletely azeotropic. This solvent system is preferred for use withacrylic polymer binders, as it dries well, is environmentally friendly,takes less energy, and is less sensitive to combustion or explosion asan azeotrope. The THF/water solvent is also preferred because the THFleaves first while drying, followed by the water, which assists inmaintaining the binder toward theta condition. Particularly, the THFleaves first due to its higher volatility than water. Exit of theorganic solvent first allows the coalescence of the film to collapse andreduce the stress. Water then dominates the solvent interface, therebyallowing the polymer to approach theta conditions.

Only a slight increase in the fraction of water over the azeotropicmixture concentrations of (e.g., 6.7 mass percent) is needed to provideoptimum coating drying. The results in solvent mixture in the range of7-8% water in 92-93% THF drying at 64° C. This lower drying temperaturehas the added benefit of reducing operating costs compared to currentmagnetic tape coating processes.

The resulting mixture (pigment+solvent) is applied onto a structure,such as the substrate 1004. Any suitable technique may be used to applythe mixture. Where the mixture of pigment and solvent form an emulsion,a preferred technique is spray coating, which provides fast, uniformapplication without streaks typical of brush coating or chunks typicalof blade coating. Other application techniques include blade coating,slot-die coating, use of gravure rolls, etc.

In another approach, forming the underlayer 1006 includes mixing thepolymeric binder with the encapsulated nanoparticles to form amicro-suspension without the addition of dispersants or other additivesto create a stable dispersion.

The applied mixture is dried to remove at least some of the solvent, orsubstantially fully dried. For example, the applied mixture may be driedso the more volatile organic solvent (e.g., THF) is removed, therebyincreasing the non-solvent content in the drying film. The polymericbinder collapses between the encapsulated microparticles as the solventis removed during the drying. For example, in one aspect in which thebinder is hydrophobic, the last solvent to leave the applied mixture iswater, a non-solvent for the binder, which thus forces the hydrophobicbinder to collapse onto the pigments. This also minimizes the residualstress in the dry coating, thereby preventing such things as tapecurling. The drying is preferably performed using forced air under lowtemperature (less than about 75° C.) conditions.

The partially dried coating which will eventually provide the underlayerfor the magnetic recording layer may be cured using, e.g., athermal-induced chemical reaction to cure the two layers, aradiation-induced chemical reaction to cure the two layers, etc. Forexample, UV light or other known radiation exposure is applied to causecrosslinking of the polymeric binder. If proper solvent selection isemployed for both coatings, the cure step results in minimal stressbetween the two layers and results in a stable (flat) coating.

In the case of thermal-induced cure, a chemical reaction may be used toreduce solvent swelling in the coating as well as improve the mechanicalproperties of the cured coating. Chemical cure in a dry film is slow andinefficient in achieving the desired uniformity of a cured highly filledcoating. The preferred approach is to use radiation-induced chemicalcure. Fortunately, all current and future magnetic recording layersemployed for tape applications are now thin enough to allow efficientmovement of light through the coating and effect chemical reactionswithin the binder-rich regions which are the target of such curereactions. It is well known that ultraviolet (UV) radiation can activatethe formation of free radicals which can attack unsaturated carbon bondssuch as olefins, vinyls and acrylates to initiate polymerization ofthese reactive species to form more rigid molecular structures. UVcuring is also preferred, as the underlayer 1006 may also bind to somesubstrates 1004 during free radical formation, thereby improvingdurability of the tape.

After curing the underlayer 1006, a magnetic recording layer 1008 isformed on or above the underlayer 1006. By drying and curing theunderlayer 1006 before forming the magnetic recording layer 1008 of anytype thereon, interlayer turbidity at the interface between theunderlayer and the recording layer is minimized. This overcomes aproblem that has been prevalent in conventional magnetic recording tapemanufacture, resulting in a limit on the achievable areal recordingdensity of the tape.

In one exemplary approach, nanoparticles of a weakly magnetic material(chromium dioxide) are coated with an aromatic polymer shell (methylenebis diphenyl carbamate with a functional acrylic polyester as the estersegment for the aromatic carbamate) and bound together with a functionalacrylic polymer. A formulation of the foregoing materials is dispersedusing ultrasonic dispersion methods into an ultraviolet (UV) curableemulsion in a tetrahydrofuran (THF) and water solvent system, appliedabove the substrate 1004, dried, and cured. The dried coating has thepigment encapsulated with the aromatic glassy polymer such that thematrix is highly filled with the magnetic and electrically conductivepigment to over 40% while maintaining an elastic, rubbery interparticlematrix formed from the polyester-acrylate regions of the carbamatebinder.

Process for Fabricating Encapsulated Magnetic Nanoparticles

In various approaches, the base magnetic nanoparticles, to beencapsulated later using any of the novel processes disclosed herein,are prepared using known techniques, e.g., milling. In other approaches,the base magnetic particles are obtained in ready-to-use form andencapsulated using any of the novel processes disclosed herein.

The formation of encapsulated magnetic nanoparticles may be performedusing various techniques. Prior approaches to encapsulate magneticnanoparticles have proven unsuccessful. Rather than attempt to maintainisolation of the encapsulated nanoparticle precursors (not yet convertedto the final magnetic state by high heat conversion), in preferredapproaches, the magnetic nanoparticles are mixed with an organic solventin which an aromatic dispersant is present. Absorption of the aromaticspecies onto the nanoparticles allows a stable suspension of theparticles in the initial solvent, such as toluene which is a goodsolvent for many appropriate aromatic dispersants. The mixture is heatedwith ultrasonic dispersion energy applied to maintain the suspension. Ahigh boiling aromatic hydrocarbon such as anthracene, phenanthrene,pyrene, etc. is added to the approximate volume of toluene prior todistillation. The mixture is heated above the boiling point of tolueneand the toluene distilled away leaving a molten suspension of thedispersed nanoparticles in the fully aromatic polyaromatic melt, such asmolten phenanthrene, which melts above 380° C.

In one illustrative approach, the mixture is heated in a pressure vesselto allow the temperature to be raised to 400° C. and held for four tosix hours. The iron nanoparticles are converted to the magnetic epsilonform of iron oxide. In this process the magnetic particles remainencased in a fully aromatic shell.

The mixture is then cooled to room temperature before processing toextract the encapsulated particles is carried out. Once cooled to roomtemperature, the waxy solid with the dispersed nanoparticles isdissolved in a solvent such as toluene to once again obtain a dispersionof the nanoparticles in the mixed aromatic solvents. To this is nowadded sufficient chloroform or the like to allow the aromatic layer toseparate and be decanted from the particles suspended in chloroform.

Dry particles can be recovered by distillation of the chloroform or asuspension maintained by solvent exchange into water to form an emulsionif the aromatic encapsulation layer is modified so as to have sufficientresidual polar functionality so that allows stable dispersion intowater.

Recording Layer

In some approaches, the recording layer 1008 is of new and novelconstruction. The new and novel recording layer 1008 may be present inthe medium 1000 with a conventional underlayer 1006 therebelow, in oneaspect. In another aspect, the new and novel recording layer 1008 may bepresent in the medium 1000 with a new and novel underlayer 1006therebelow. In other approaches, the recording layer 1008 is ofconventional construction, and is present in the medium 1000 with a newand novel underlayer 1006 therebelow.

In approaches where the recording layer 1008 is of conventionalconstruction, a dispersion of weakly magnetic particles dispersed in abinder system which does not attempt to encapsulate the particles in aglassy encapsulating layer prior to dispersion may be used as the fluxdissipation layer as has been practiced in the construction of currenttape media for over a decade. These underlayers may or may not haveadditional particles added for conductivity or abrasive strengthimprovement.

In preferred approaches, the recording layer 1008 includes a newformulation in which the recording layer 1008 includes encapsulatednanoparticles 1018 each comprising at least one magnetic nanoparticle1020, and preferably only a single magnetic nanoparticle 1020,encapsulated by an encapsulating layer 1022, and a polymeric binder 1024binding the encapsulated nanoparticles. In general, the magneticstrength of the magnetic nanoparticles in the recording layer 1008 issignificantly greater than the magnetic strength of nanoparticles in theunderlayer 1006, if present.

An average concentration of the encapsulated nanoparticles in therecording layer 1008 is preferably at least about 35% by weight (wt %),e.g., about 45-50% wt %, in a range of about 35-50 wt %, preferably in arange of about 46-50 wt %, or any other sub-range within theaforementioned ranges.

The magnetic nanoparticles in the encapsulated nanoparticles of therecording layer 1008 may be constructed of any magnetic materialsuitable for the intended application, such as magnetic recording.Moreover, magnetic materials usable in magnetic imaging may be used inthe magnetic nanoparticles in some approaches. In various approaches,the magnetic nanoparticles include at least one magnetic materialselected from the group consisting of: alloys and/or oxides of nickel,cobalt, and iron including mixed compounds and crystals usingcombinations of nickel, cobalt, and iron such as: iron-barium, NiFe,barium ferrite, and cobalt platinum.

It should be noted that the approach described herein is applicable toother nanoparticles currently not typically useful for tape storagelayers such as MnAl and even non-magnetic dispersions which couldbenefit from improved control of the coating integrity such as SiC andSiO₂ dispersions useful in sand papers and other abrasives. Accordingly,any known type of magnetic nanoparticle may be used in variousapproaches.

In preferred approaches, the magnetic nanoparticles include at least onemagnetic material selected from the group consisting of: Co₃O₄, CoFe,Fe₃O₄, alpha iron oxide (α-Fe₂O₃), epsilon iron oxide (ε-Fe₂O₃), andCo(fcc). In other approaches, the magnetic nanoparticles may includemanganese aluminum alloys, oxides of magnetic metals, and pinelferrites.

An average diameter of the magnetic nanoparticles in the recording layer1008 is preferably in a range of about 2 nm to about 20 nm, preferablyin a range of about 2 nm to about 10 nm, especially for the epsilon ironoxide particles. The average diameter could be higher or lower than thisrange in depending on the size at which the magnetic nanoparticle losesits remanence and becomes superparamagnetic. In general, a smalleraverage diameter is better for purposes of increasing bit resolution.

Preferably, the encapsulated nanoparticles used in the recording layerhave the same composition, crystal structure and morphology as well as avery narrow particle size range to optimize the final recording layerresponse to an applied external field during data writing. In preferredapproaches, greater than about 80% of the encapsulated nanoparticleshave only a single magnetic nanoparticle therein, more preferablygreater than about 90, even more preferably greater than about 98%, andideally at least about 100% of the encapsulated nanoparticles have onlya single magnetic nanoparticle therein.

The aromatic polymer encapsulating the magnetic nanoparticles may beand/or include any of many different aromatic polymers, as long as thearomatic polymer encapsulates at least about 75% of the surface of themagnetic nanoparticle, preferably at least about 90% of the surface ofthe magnetic nanoparticle, and ideally approximately 100% of themagnetic nanoparticle in the underlayer 1006 and especially foroptimization of the magnetic nanoparticles in the recording layer. Inthe recording layer, the efficiency of the particle encapsulation shouldbe as close to 100% as can be obtained by a viable process used toconstruct large quantities in practice. Accordingly, the aromaticpolymer forms at least a partial shell, and preferably a full shell,around the magnetic nanoparticles. An average thickness of the aromaticpolymer encapsulating the magnetic nanoparticles is preferably less than1 nm in the final recording layer 1008. Preferably, the averagethickness of the aromatic polymer shell is in a range of about 0.5 nm toabout 1 nm, e.g., 0.5-0.75 nm, 0.6-0.8 nm, 0.7-1 nm, 0.8-1 nm, etc. butcould be slightly higher or lower than these ranges. In some instances,clusters or aggregates of partially coated nanoparticles may be formedduring the encapsulating process which may persist through theformulation process into the final coating. So long as these clustersand aggregates are not a significant fraction of the coating (e.g., lessthan 10% by volume) and smaller than the final coating thickness so asnot to impart surface roughness and defects (e.g., <60% the thickness ofthe final dried coating in diameter) the presence of clusters andaggregates should not be limiting on the desired functionality of thelayer.

In embodiments where the encapsulated nanoparticles are pyrolyzed, theaverage thickness of the resulting carbon shell is in a range of about0.05 nm to about 1 nm.

Such thin shells improve magnetic particle packing density in therecording layer 1008, and thus enable higher recorded bit resolution.

Aromatic structures are preferred as the encapsulating layer for theisolation of magnetic nanoparticles due to their unique electronicproperties which provide some weak but significant separation of eachnanoparticle from the magnetic field coupling them with their nearneighbors in the final close-packed dry coating.

The aromatic polymer preferably includes functional groups that have anaffinity to adhesion to iron oxide where iron magnetic nanoparticles areused. Illustrative functional groups include carboxylate functionalgroups, nitrile functional groups, and others.

A preferred aromatic polymer is a radiation curable substituted aromaticpolymer. In another approach, the aromatic polymer is a styrene, such aspolystyrene. Ideally, the aromatic polymer is polystyrene with acopolymer which has a rubbery polymer chain in the para-position on thestyrene monomer. Preferably, the encapsulating layer includes apolyaromatic film.

In other approaches, the aromatic polymer is one that is a knownprecursor usable for creating graphite, carbon fiber, carbon nanotubes,etc. Accordingly, the encapsulating layer may be a graphite-likedominated continuous film.

The polymeric binder binding the encapsulated nanoparticles together maybe and/or include various types of binder material.

Contemplated approaches attempted to incorporate encapsulated magneticnanoparticles into conventional binder systems, but it was found thatsuch approaches result in recording layers that have far more noise andmuch poorer signal performance than would be predicted from theassumption that the particles are smaller and more packed into anoriented film. While the reason for such poor performance in approachesusing conventional binder systems is not completely understood, theinventor has found that the novel techniques described herein result ina new recording layer that exhibits excellent recording performance, farsuperior to said approaches using conventional binder systems.

In preferred approaches, the binder includes an acrylic polymer, e.g., apolymer of acrylic acid or an acrylate, and preferably a functionalacrylic polymer. In particularly preferred approaches, the polymericbinder includes a radiation curable rubbery acrylic polymer.Illustrative acrylic polymers suitable for use as a binder in variousapproaches include acrylic terminated polyester, and those that includecomponents such as methyl methacrylate, acrylic acid, and others. Forexample, the binder may include an acrylic terminated aliphaticpolyester or aliphatic polyether polymer. In general, preferredpolymeric binders are those with a number average molecular weight ofless than about 2400, and preferably less than about 1200.

The binder used in the recording layer 1008 may be the same as, ordifferent than, the binder used in the underlayer 1006, in variousapproaches.

The recording layer 1008 should be flexible (rubbery) over the in-useoperating temperature range, while providing tear resistance and shockresistance. Accordingly, preferred embodiments result in a recordinglayer 1008 that has a glass transition temperature in excess of about35° C., preferably in excess of about 45° C., and ideally at least about50° C. This can be achieved via selection of the binder.

Additional materials may be present in the recording layer 1008, such aslubricants. However, one benefit of various approaches disclosed hereinis that they allow the elimination of conventional additives such aswear particles to the recording layer.

An average thickness of the recording layer 1008 as measuredperpendicular to the plane of formation thereof is less than about 0.2microns, and preferably less than about 0.1 micron. One benefit of thisthickness of recording layer 1008 is that the UV light is able to reachall portions of the recording layer 1008 even with the pigment therein,thereby ensuring a fast, consistent cure throughout the layer.Conventional recording layers, being thicker, were unable to be UVcured, and therefore relied upon other types of curing that were not asfast. Accordingly, as the conventional tape was formed, curing continuedas the tape was wound onto a spool. However, winding the tape onto thespool created tensions and stresses (e.g., radial compression)throughout the tape, resulting changes in the mechanical characteristicsof the tape that varied from the tape at the inside of the hub to thetape at the outside of the hub.

Where the recording layer 1008 is formed directly on an underlayer 1006,the recording layer 1008 is preferably applied after curing of theunderlayer 1006 to minimize interlayer turbidity. Accordingly, inpreferred approaches, the recording layer 1008 is substantially notintermixed with the underlayer 1006 (and vice versa).

Preferably, the underlayer 1006 has a bulk magnetic field strength in Oethat is less than 200 Oe, and preferably less than 100 Oe. Theunderlayer 1006 may have similar construction and/or characteristics asthe underlayers disclosed elsewhere herein.

In some aspects, lubricant molecules 1030 are coupled to a surface ofthe recording layer 1008. The lubricant molecules may be bound to thesurface, embedded in the surface, or both. Preferably, the amount of thelubricant molecules along the surface of the recording layer 1008 isless than an amount that would form a continuous lubricant film alongthe surface of the recording layer 1008.

In preferred approaches, no wear particles are present in the recordinglayer 1008, and ideally, no wear particles are present in the product atall. However, in other approaches, wear particles may be present in therecording layer 1008 and/or pass therethrough from an underlayer 1006.It is expected that the foregoing mechanical design of the recordinglayer 1008 with an electrically conductive underlayer 1006 will achievethe desired low friction and head corrosion properties of the tapesurface without the need for the inclusion of wear particles, whichconstitute an increasingly intolerable defect and source of damage tothe shrinking read and write structures in current and future recordingheads.

Process for Fabricating Recording Layer

A method for fabricating the recording layer 1008, e.g., of a magneticrecording medium, in accordance with various approaches, is presentedbelow. As an option, the present method may be implemented to fabricaterecording layers 1008 such as those described above. Of course, however,this method and others presented herein may be used to form recordinglayers 1008 which may or may not be related to the illustrative aspectslisted herein. Further, the methods presented herein may be carried outin any desired environment. Moreover, more or less operations than thosedescribed below may be included in the method, according to variousapproaches. It should also be noted that any of the aforementionedfeatures may be used in any of the approaches described in accordancewith the various methods.

The method generally includes forming a magnetic recording layer 1008having encapsulated nanoparticles each comprising at least one magneticnanoparticle encapsulated by an aromatic polymer, and a polymeric binderbinding the encapsulated nanoparticles.

In one approach, forming the recording layer 1008 includes heating themagnetic nanoparticles and aromatic polymer to a temperature thatresults in a suspension of the magnetic nanoparticles in the aromaticpolymer. In general, for most aromatic polymers, the temperature is in arange of about 200 degrees Celsius to about 538 degrees Celsius,depending on the aromatic polymer used.

Where the aromatic polymer has a simple aromatic structure, atemperature of less than 200 degrees Celsius may be used. The relativeamounts of magnetic nanoparticles and aromatic polymer in the suspensionare preferably selected to provide characteristics listed in theprevious section, as well as to avoid creating clusters ofnanoparticles.

An organic solvent may be mixed with the nanoparticles and aromaticpolymer to create a suspension that prevents clustering and sintering ofthe nanoparticles. Such solvents may include molten aromatic solventssuch as phenanthrene. Preferably, the solvent is one that does notresult in oxidative reactions with the magnetic nanoparticles. Tolueneor the like may also be added to shift the mixture more toward anemulsion.

In some approaches, the encapsulated particles are pyrolyzed, resultingin a magnetic nanoparticle that is encapsulated in a carbon shell.

The warm suspension of magnetic nanoparticles and aromatic polymer ismixed with a polymeric binder and a solvent to form a mixture.Ultrasonic dispersion is preferably used to create an emulsion. Thistechnique of encapsulated nanoparticle synthesis and polymerencapsulation beneficially eliminates the need for milling andredispersion from aggregated clusters of particles, as is typical inconventional fabrication techniques.

In general, the solvent mixture should provide one or more, andpreferably all, of the following characteristics: the most volatilesolvent (first to leave during drying) causes the polymeric binder toswell, the second or last solvent to leave during drying is ideally apoor solvent for the binder so that during drying the solution passesthrough theta conditions for that binder and forces the binder tocollapse around the pigment, rather than shrinking during drying whichresults in undesirable stress in the final coating. The last solvent toleave during drying, being a non-solvent for the binder, forces theswollen chains to coil into their minimum free volume state, referred toas the theta condition, as it passes from being well solvated by thefirst solvent to being encased in a non-solvent rich environment duringdrying. The layer is most stable when the polymeric binder is in thetacondition, and it is at this point where the curing should occur. UVcuring is preferred when the polymeric binder is close to its thetacondition due to the speed at which curing occurs.

A preferred solvent is a water and THF solvent system in relativeconcentrations that render the solvent system predominately azeotropicwith a slight excess of water to force the final drying coating to passthrough theta conditions during drying. The THF leaves first due to itshigher volatility than water. Exit of the organic solvent first allowsthe coalescence of the film to collapse and reduce the stress. Waterthen dominates the solvent interface, thereby allowing the polymer toapproach theta conditions.

In other approaches, the system may be dominated by water such that thecoating is a true emulsion, with the absorbed binder acting as anemulsifier as well as providing the rubber phase resin in the finalcoating. In further approaches, the useful solvents may include mixturesof volatile polar organics with higher boiling non-solvents for thebinders like MEK/Toluene, Acetone/Methyl Isobutyl Ketone, etc.

The resulting emulsion/solvent is applied onto a structure, such as theaforementioned underlayer 1006, or another substrate. Any suitabletechnique may be used to apply the emulsion/solvent. A preferredtechnique is specially designed low pressure high volume spray coating,which provides fast, uniform application without streaks typical ofbrush coating or thickness variations and modulation of the interfacesthat result from high shear blade or die extrusion coating methods forthese very thin coatings.

The applied mixture is partially dried to remove at least some of thesolvent, or substantially fully dried. The polymeric binder collapsesonto the encapsulated microparticles as the solvent is removed duringthe drying. For example, in one aspect in which the binder ishydrophobic, the last solvent to leave the applied mixture is water, anon-solvent for the binder, which thus forces the hydrophobic binder tocollapse onto the pigments. This also minimizes the residual stress inthe dry coating. The drying is preferably performed using forced airunder low temperature (less than about 75° C.) conditions.

The at least partially dried applied mixture is cured to restrictfurther expansion or contraction in the as-coated, stress-relievedlayers during subsequent processing and exposure to environmentalstresses to create a thin, high density recording layer 1008 havingclose-packed magnetic nanoparticles. In one approach, the at leastpartially dried applied mixture is irradiated. For example, UV light orother known radiation exposure is applied to cause crosslinking of thepolymeric binder. In another approach, a different curing process isperformed, such as by heating to increase reaction of thermally reactivefunctional groups in the encapsulated nanoparticle layer with therubbery binder phase of the dried film.

As an option, lubricant may be added during formation of the recordinglayer 1008, the lubricant molecules 1030 eventually becoming coupled toa surface of the recording layer 1008 upon formation of the recordinglayer 1008. The lubricant molecules may be bound to the surface,embedded in the surface, or both. Again, preferably, an amount of thelubricant molecules along the surface of the recording layer 1008 isless than an amount to form a continuous lubricant film along thesurface of the recording layer 1008. In one illustrative approach, thelubricant molecules are positioned apart, on average, center to center,a distance in a range of about 2 to about 15 molecular radii along thesurface of the recording layer 1008.

In one approach, lubricant molecules 1030 are dispersed in the organicsolvent phase and are carried to the surface during drying where theyare grafted to the surface during the curing so that they form a stablelow friction layer without movement of the lubricant molecules to thedrive bearing and head surfaces. This in turn reduces headcontamination.

In other approaches, a lubricant is applied to the outer surface of thecompleted recording layer 1008.

In one illustrative example, a predominantly monodisperse suspension ofmagnetic nanoparticles such as Co₃O₄, CoFe, Fe₃O₄, or Co(fcc)encapsulated with an aromatic polymer is combined with a rubbery polymerwith radiation-curable end groups and side chains of sufficient chainlength to provide a rubbery phase when bounded during cure to radiationcurable end groups on the aromatic encapsulating layers of the dispersednanoparticles. The resulting suspension is used to construct a closepacked, thin recording layer 1008 in which a high density recording canbe recorded. The rubbery chain attached to the aromatic encapsulatinglayer is terminated with an acrylic or methacrylic functional groupcapable of being UV cured to form a highly crosslinked matrix in whichthe magnetic particles are fully encapsulated by an aromatic glassypolymer held into a cohesive coating through swelling of the rubberyphase, e.g., acrylic terminated low molecular weight polyester added tothe solvent. UV curing of the solvent-swollen coating and polyester iscarried out during drying.

Relative to current magnetic recording media, various benefits of amagnetic recording tape having the new underlayer and new recordinglayer thereon include, but are not limited to, one or more of: thinnerrecording layer, more uniform magnetic particle dispersion, smoother,less turbid interface between the underlayer and recording layer, higherglass transition temperature, lower occurrence or essential eliminationof voids of magnetic particles in the recording layer, etc. Each ofthese benefits results in a magnetic recording tape that exhibitscharacteristics such as, but not limited to, one or more of: higherdimensional stability, greater tear resistance, higher recordingresolution down to and below 1 nm, lower noise resulting in a highersignal to noise ratio, etc.

It will be clear that the various features of the foregoing systemsand/or methodologies may be combined in any way, creating a plurality ofcombinations from the descriptions presented above.

It will be further appreciated that embodiments of the present inventionmay be provided in the form of a service deployed on behalf of acustomer.

The inventive concepts disclosed herein have been presented by way ofexample to illustrate the myriad features thereof in a plurality ofillustrative scenarios, embodiments, and/or implementations. It shouldbe appreciated that the concepts generally disclosed are to beconsidered as modular, and may be implemented in any combination,permutation, or synthesis thereof. In addition, any modification,alteration, or equivalent of the presently disclosed features,functions, and concepts that would be appreciated by a person havingordinary skill in the art upon reading the instant descriptions shouldalso be considered within the scope of this disclosure.

The descriptions of the various embodiments of the present inventionhave been presented for purposes of illustration, but are not intendedto be exhaustive or limited to the embodiments disclosed. Manymodifications and variations will be apparent to those of ordinary skillin the art without departing from the scope and spirit of the describedembodiments. The terminology used herein was chosen to best explain theprinciples of the embodiments, the practical application or technicalimprovement over technologies found in the marketplace, or to enableothers of ordinary skill in the art to understand the embodimentsdisclosed herein.

What is claimed is:
 1. A product, comprising: a recording layercomprising: encapsulated nanoparticles each comprising a magneticnanoparticle encapsulated by an encapsulating layer, and a polymericbinder binding the encapsulated nanoparticles.
 2. The product as recitedin claim 1, wherein the magnetic nanoparticles include at least onemagnetic material selected from the group consisting of: nickel, cobalt,and iron.
 3. The product as recited in claim 1, wherein the magneticnanoparticles include at least one magnetic material selected from thegroup consisting of: Co₃O₄, CoFe, Fe₂O₃, Fe₃O₄, and Co(fcc).
 4. Theproduct as recited in claim 1, wherein an average diameter of themagnetic nanoparticles is in a range of 2 nanometers to 20 nanometers.5. The product as recited in claim 1, wherein the encapsulating layer isa layer selected from the group consisting of: a polyaromatic film, anda graphite-like dominated continuous film.
 6. The product as recited inclaim 1, wherein an average thickness of each encapsulating layer isless than 1 nanometer.
 7. The product as recited in claim 1, wherein thepolymeric binder which binds the encapsulated nanoparticles is aradiation curable rubbery acrylic polymer.
 8. The product as recited inclaim 1, wherein an average thickness of the recording layer is lessthan 0.2 microns.
 9. The product as recited in claim 1, wherein anaverage thickness of the recording layer is less than 0.1 microns. 10.The product as recited in claim 1, wherein no wear particles are presentin the recording layer.
 11. The product as recited in claim 1, whereinno wear particles are present in the product.
 12. The product as recitedin claim 1, comprising an underlayer, the recording layer being formedon the underlayer.
 13. The product as recited in claim 12, wherein therecording layer is substantially not intermixed with the underlayer. 14.The product as recited in claim 12, wherein the underlayer iselectrically conductive.
 15. The product as recited in claim 12, whereinthe underlayer comprises magnetic nanoparticles having an averagemagnetic field strength of less than 200 Oersted (Oe).
 16. The productas recited in claim 1, comprising lubricant molecules coupled to asurface of the recording layer, wherein an amount of the lubricantmolecules along the surface of the recording layer is less than anamount to form a continuous lubricant film along the surface of therecording layer.
 17. The product as recited in claim 1, wherein theencapsulating layer includes an aromatic polymer.
 18. The product asrecited in claim 1, wherein the recording layer is part of a magneticrecording tape.
 19. A product, comprising: a recording layer comprising:encapsulated nanoparticles each comprising a magnetic nanoparticleencapsulated by an encapsulating layer, and a polymeric binder bindingthe encapsulated nanoparticles, wherein an average diameter of themagnetic nanoparticles is in a range of 2 nanometers to 20 nanometers,wherein an average thickness of the recording layer is less than 0.2microns.
 20. The product as recited in claim 19, wherein theencapsulating layer is a layer selected from the group consisting of: apolyaromatic film and a graphite-like dominated continuous film.
 21. Theproduct as recited in claim 19, wherein an average thickness of eachencapsulating layer is less than 1 nanometer.
 22. The product as recitedin claim 19, wherein the polymeric binder includes a material selectedfrom the group consisting of: a radiation curable rubbery acrylicterminated aliphatic polyester and an aliphatic polyether polymer. 23.The product as recited in claim 19, wherein no wear particles arepresent in the product.
 24. The product as recited in claim 19,comprising lubricant molecules coupled to a surface of the recordinglayer.
 25. The product as recited in claim 24, wherein an amount of thelubricant molecules along the surface of the recording layer is lessthan an amount to form a continuous lubricant film along the surface ofthe recording layer.